Handling Abnormal Conditions
This scenario demonstrates how operators and supervisors at Blueprint Paper Mill use Cyzag Blueprint to detect, document, and respond to equipment issues and out-of-range readings.
Scenario 1: Digester High Pressure Event
Date: June 18, 2025 Time: 6:10 AM Operator: Sarah Johnson (Pulping Operator) Asset: Digester D-101
Event Detection
During the Morning Shift - Pulping Round, Sarah records digester readings:
- Cooking Temperature: 171 °C ✅ (normal: 165–172 °C)
- Digester Pressure: 6.1 bar 🔴 (normal: 5.2–5.8 bar, alert: >6.0 bar)
- H-Factor: 1180 ✅
- White Liquor Flow: 41 L/min ✅
- Chip Level: 75% ✅
App Response
When Sarah enters 6.1 bar, the app:
- Field turns red 🔴
- Alert: "Above safe operating range (>6.0 bar)"
- Forces operator to add notes (required, not optional)
Sarah adds:
Pressure spike observed. Checked relief valve - appears
to be functioning. May be transient spike from cooking
cycle. Will monitor.
She captures a photo of the pressure gauge.
Automatic Escalation
The app:
- Creates Observation #142 with Severity: High (pressure excursions are safety-critical)
- Sends immediate notification to supervisor (Maria Lopez)
- Flags asset status as "⚠️ Attention Required"
Supervisor Response (6:12 AM)
Supervisor Maria Lopez receives notification on her phone:
🚨 High Priority Observation
Digester D-101 - High Pressure
6.1 bar (above 6.0 bar safe limit)
Operator: Sarah Johnson
Time: 6:10 AM
[View Details]
Maria immediately:
- Reviews trend graph: Pressure was 5.7 bar yesterday, 5.8 bar two days ago – trending upward
- Calls Sarah: Confirms situation is stable
- Instructs Sarah: "Reduce white liquor flow by 10% and monitor pressure every 30 minutes"
- Adds comment to observation: "Flow rate adjusted. Monitoring every 30 min. Pressure relief valve inspection scheduled for day shift."
Follow-Up Readings
Sarah continues monitoring:
6:40 AM: Pressure 5.9 bar ⚠️ (trending down, still above normal) 7:10 AM: Pressure 5.7 bar ⚠️ (within normal range) 7:40 AM: Pressure 5.6 bar ✅ (normal, stable)
Resolution
At 8:00 AM, day shift maintenance inspects the pressure relief valve and finds it partially clogged. Valve cleaned and tested. Observation #142 marked Resolved with notes:
Pressure relief valve cleaned. Valve was partially
obstructed, reducing relief capacity. Valve now tested
and operating correctly. Digester pressure stable at
5.5 bar. No further action required.
Resolved by: Maintenance Technician Mike Chen
Time: 8:45 AM
Outcome
- Early detection: Pressure issue identified during routine round
- Rapid response: Supervisor notified within 2 minutes
- Effective action: Temporary adjustment + root cause fix
- Prevented escalation: Avoided potential safety incident or equipment damage
- Complete documentation: Full audit trail from detection through resolution
Scenario 2: Dryer Can Temperature Trending
Date: June 20–24, 2025 Operator: Multiple (rotating shifts) Asset: Dryer Can DC-12
Trending Issue Detected
Over 5 consecutive days, Dryer Can DC-12 surface temperature readings show an upward trend:
| Date | Time | Operator | Surface Temp | Status |
|---|---|---|---|---|
| Jun 20 | 8:00 AM | John Smith | 88 °C | ✅ Normal |
| Jun 21 | 8:05 AM | Sarah Johnson | 89 °C | ✅ Normal |
| Jun 22 | 8:02 AM | John Smith | 91 °C | ✅ Normal |
| Jun 23 | 8:07 AM | Mike Chen | 93 °C | ⚠️ Near limit |
| Jun 24 | 8:03 AM | Sarah Johnson | 95 °C | ⚠️ At upper limit |
Normal range: 85–95 °C
Proactive Investigation
Although all readings are technically "within normal range," the trend is concerning. On June 24, supervisor Maria Lopez:
- Reviews trend graph: Clear upward trajectory approaching upper limit
- Creates manual observation (not triggered automatically):
Observation #158
Asset: Dryer Can DC-12
Condition: Upward Temperature Trend
Severity: Medium
Temperature trending upward over 5 days (88°C → 95°C).
Now at upper limit. Recommend inspection of steam trap
and condensate removal system before temperature
exceeds safe range.
Created by: Maria Lopez (Supervisor)
Time: 8:30 AM, June 24
- Schedules inspection: Day shift maintenance to inspect during planned production pause
Investigation Results
Maintenance discovers blocked condensate line preventing proper condensate removal. Line cleared and steam trap replaced.
June 25, 8:00 AM: Temperature drops back to 89 °C ✅
Outcome
- Trend analysis prevented issue: Caught problem before temperature exceeded limits
- Proactive maintenance: Fixed before impacting product quality or safety
- Supervisor judgment: System provided data; supervisor made intelligent decision
- Observation documented reasoning: Future reference for similar patterns
Scenario 3: Cooling Tower Algae Growth
Date: June 21, 2025 Time: 6:38 AM Operator: John Smith (Utility Operator) Asset: Cooling Tower CT-03
Visual Inspection Finding
During the Morning Shift - Utilities Round, all Cooling Tower CT-03 readings are normal:
- Fan Vibration: 2.6 mm/s ✅
- Water Temperature: 27 °C ✅
- Fan Noise Level: Normal ✅
However, John notices visible algae buildup on the south side of the tower basin during visual inspection.
Manual Observation Creation
John selects "Yes" for the checkbox "Visible algae growth?" and adds:
Algae buildup on south side of basin. Approximately 20%
of basin surface affected. Not yet impacting water flow
but will get worse if not addressed. Recommend cleaning
within next week before buildup spreads.
He captures photo showing green algae on basin walls.
Supervisor Review
Observation #153 flagged as Severity: Low (not urgent, but requires follow-up).
Supervisor schedules basin cleaning for Saturday maintenance (5 days away, during planned downtime).
Resolution
June 26: Cleaning crew cleans basin, removes algae, and treats water with biocide. Observation marked Resolved.
Outcome
- Preventive action: Issue documented before impacting operations
- Photo evidence: Clear visual record for maintenance planning
- Appropriate priority: Low-severity observation handled during planned downtime
- Trend tracking: If algae returns, historical record shows frequency and severity
Key Patterns in Abnormal Condition Handling
1. Automatic vs. Manual Observations
Automatic (system-created):
- Out-of-range numeric readings
- Failed pass/fail checks
- Severity determined by how far outside range
Manual (operator/supervisor-created):
- Trending issues (values within range but changing)
- Visual conditions (leaks, wear, corrosion)
- Unusual sounds, smells, or behavior
2. Severity Levels
- Critical: Safety risk, equipment at risk of failure, production stopped
- High: Exceeds safe limits, requires immediate action
- Medium: Outside normal range, needs attention soon
- Low: Noted for follow-up, not urgent
3. Response Workflow
- Detection: Operator records abnormal reading or condition
- Flagging: App creates observation and notifies supervisor
- Review: Supervisor assesses severity and context (trends, history)
- Action: Supervisor directs immediate action or schedules maintenance
- Follow-up: Operator monitors or maintenance resolves issue
- Resolution: Observation closed with notes explaining outcome
4. Phase 2 Enhancements (Future)
Current Phase 1 capabilities will be enhanced in Phase 2 with:
- Automated severity classification based on rule engine
- Alert escalation if observations not acknowledged within time threshold
- Triage workflows (acknowledge, assign, escalate)
- Integration with work order systems for automatic work request creation
Next Steps
Explore related scenarios:
- Daily Operations – Routine rounds and normal conditions
- Shift Handover – Transferring observations between shifts
Or try the hands-on tutorial:
- Blueprint Paper Mill Tutorial – Learn observation workflows